Althouse • Turnquist • Bracciano

PowerPoint Presentation by:

Associated Technical Authors

Publisher
The Goodheart-Willcox Company, Inc.
Tinley Park, Illinois
Chapter 5
 Explain the purpose and operation of
refrigerant control devices.
 Name the six main types of controls and
explain their operation.
 Define terms related to refrigerant control
operations.
 Compare the various charging elements
used on refrigerant controls.
 Explain the fast evaporation of liquid into a
vapor.
 Determine the proper size capillary tube to
be used for specific applications.
 Explain the operation of special refrigerant
controls.
 Define the purpose and function of three
types of solenoid valves.
 Follow approved safety procedures.
5.1
Refrigerant Control

• Used in a refrigeration system to change the

pressure of the refrigerant.
• Is placed between the liquid line and the evaporator.
• Reduces the high pressure in the liquid line to low
pressure in the evaporator.
 Six Types of
Refrigerant Controls

• Automatic Expansion Valve (AEV).

• Thermostatic Expansion Valve (TEV).
• Low-Pressure Side Float (LSF).
• High-Pressure Side Float (HSF).
• Capillary Tube (Cap Tube).
• Thermal-Electric Expansion Valve.
5.1.1
Automatic Expansion Valve

• Operated by low-side pressure as the closing force

and spring pressure as the opening force.
• Throttles liquid refrigerant in the liquid line down to
a constant pressure. While compressor is running,
liquid refrigerant is sprayed into the evaporator.
• Sometimes called a dry system, since evaporator is
never filled with liquid refrigerant, but with a mist.
• Valve capacity should equal the evaporator capacity.
5.1.1
Automatic Expansion Valve
 Bellows Automatic
5.3
Expansion Valve

• Valve seat is softer than needle.

• Spring is attached at both ends.
• May be adjusted for either pressure or tension.
• Attached to the evaporator by threaded fittings or a
two-bolt flange.
• Used mainly on domestic air conditioning units or
vending machines.
 Bellows Automatic
5.1.1
Expansion Valve
 Diaphragm Automatic
5.1
Expansion Valve

• Has stops to prevent excessive movement of the

diaphragm.
• Diaphragm separates the atmospheric pressure and
the system pressure.
• Three forces control valve:
• Adjustable spring.
• Spring beneath diaphragm.
• Outlet pressure underneath the diaphragm.
 Diaphragm Automatic
5.1
Expansion Valve
 Thermostatic
5.1.2
Expansion Valve (TEV)

• Sensing bulb — includes liquid-charged, gas-charged,

liquid cross-charged, and gas cross-charged.
• Note: Liquid-charged and gas-charged use the same
refrigerant in the system and bulb. Cross-charged uses
a fluid in the sensing bulb different from the system
refrigerant.
5.1.2
TEV

• Flow is through the valve into the evaporator.

• Low-side pressure, the temperature of the evaporator
outlet, and spring pressure control flow.
• Provides a high flow rate as the evaporator empties
(warms).
• Reduces flow as the evaporator fills (cools) with
refrigerant.
5.1.2
Operation of TEV

• With unit running, temperature in sensing bulb is 10°F

(5.6°C) warmer than the refrigerant temperature in
the evaporator.
• This temperature difference produces different
pressures and different forces. This is described as the
superheat of the bulb over the refrigerant
temperature inside the evaporator.
• The pressure in the sensing bulb is greater than the
pressure in the evaporator.
• As temperature increases or decreases, the pressure
will also increase or decrease.
5.1.2
Operation of TEV
5.1.2
Operation of TEV
continued

• When compressor stops, low-side pressure and the

sensing bulb pressure tend to equalize.
• The needle is forced into its seat. Refrigerant flow
stops.
5.1.2
TEV Design

• The liquid and evaporator lines are connected to the

brass valve body.
• Needle and seat are inside the body.
• Needle is joined to a flexible metal bellows or
diaphragm.
• Bellows is moved by a rod connected at the other end
to a sealed bellows or diaphragm and sensing
element.
5.1.2
TEV Design
5.1.2
TEV Design
continued

• The diaphragm is joined to the sensing bulb by means

of a capillary tube.
• Fluid that charges the sensing element is labeled by
color, letter, or number by manufacturer.
• A strainer located between the liquid line connection
and orifice keep dirt from the needle and seat.
 Questions

• Where is a refrigerant control located in the refrigeration

system? Between the liquid line and the evaporator.

• What is the purpose of a refrigerant control in a

refrigeration system?
It changes the high-pressure, high-temperature liquid to
a low-pressure, low-temperature liquid.
• Which pressures operate the automatic expansion valve?
The spring pressure is the opening force and the
low-side pressure is the closing force.
 Questions
continued

• Which type of motor control can be used with the

automatic expansion valve system?
A temperature control.

• Which types of thermostatic expansion valves use the

same refrigerant in the system as in its sensing bulb?
The liquid-charged bulb and gas-charged bulb.

• What are three operating pressures of a TEV?

Low-side pressure, sensing bulb pressure, and
spring pressure.
 Questions
continued

• What happens to the quantity of refrigerant in the

evaporator of a TEV system as the temperature of the
sensing bulb increases?
The quantity of refrigerant increases.

• Do the pressures of a TEV system equalize during the off

cycle?
No.

• What is commonly located before the inlet of a TEV?

A strainer.
5.1.2
Flash Gas

• Refrigerant that evaporates instantly (flashes) and

turns into a vapor while passing through the
refrigerant control orifice.
• The instant vaporizing of some of the liquid refrigerant
cools the remaining liquid to the evaporating
temperature.
• Amount of flash gas depends upon the temperature of
the refrigerant in the liquid line and the pressure inside
the evaporator.
• Flash gas reduces the valve capacity.
• The amount of flash gas can be reduced by clamping
the liquid line to the suction line.
5.1.2
Superheat

• The difference in temperature between the vapor in the

low side and in the sensing bulb.
• Increasing superheat starves the evaporator; only part
of the evaporator is filled with liquid refrigerant.
5.1.2
Superheat
 Liquid-charged
5.1.2
Sensing Element

• Sensing element is charged with the same refrigerant

as the system.
• Maintains a constant superheat, or compressor
superheat setting, even though low-side pressures and
temperatures change.
• Sensing element controls thermostatic valve operation.
 Liquid-charged
5.1.2
Sensing Element
 Liquid Cross-charged
5.1.2
Sensing Element

• Uses a liquid different from the refrigerant in the

system.
• Some liquid is always present in the element,
regardless of temperature.
• Valve closes quickly when the compressor stops.
• Load on compressor is reduced at startup.
• As suction pressure is reduced, superheat is reduced.
• Valve is more responsive to changes in suction pressure
than to changes in sensing bulb temperature.
 Liquid Cross-charged
5.1.2
Sensing Element
 Gas Cross-charged
5.1.2
Sensing Element

• Uses the same refrigerant as the system.

• Charge provides that all liquid is vaporized at a
predetermined temperature.
• Designed for temperature range from 30°F to 60°F
(–1.1°C to 15.6°C).
 Gas Cross-charged
5.1.2
Sensing Element
 Gas Cross-charged
5.1.2
Sensing Element (Adsorption)

• Sensing bulb is charged with a liquid different from

the system refrigerant.
• At the desired temperature, all the liquid has
vaporized.
• Some elements contain two substances: one is a non-
condensing gas, such as carbon dioxide, that provides
the pressure in the element. The other is a solid, such
as carbon, silica gel, or charcoal. These substances
can adsorb gas.
 Gas Cross-charged Sensing Element
5.1.2
(Adsorption)
continued

• Adsorption, the ability of a substance to adsorb gas;

depends upon temperature.
• Gas is more readily adsorbed at low temperatures.
• Sensing elements rely on adsorption to control the
refrigerant needle valve opening in the thermostatic
expansion valve.
• Pressure-temperature lag in operation allows for use
on any refrigeration or air conditioning system.
 Thermal-Electric (Solid State)
5.1.2
Expansion Valve

• Depends on the use of thermistors, which are directly

exposed to the refrigerant in the suction line, to
control the expansion valve needle opening.
• Refrigerant flow is controlled by the temperature in
the suction line.
• Bleed valves have a small slot in the valve seat,
allowing pressure to balance during the off cycle.
• Allows for use of low-starting-torque compressor
motors.
 Thermal-Electric (Solid State)
5.1.2
Expansion Valve
 Expansion Valve
5.1.2
with Pressure Limiters

• Prevents overloading the condensing unit.

• Designed for systems in which the evaporator
pressure must not exceed a safe operating limit.
• Consists of a diaphragm and a spring placed between
the sensing element and the needle valve.
• Diaphragm will collapse if low-side pressure exceeds a
certain set value.
• May be mechanical (conventional) or pressure-
limiting (MOP: maximum operating pressure).
 Expansion Valve
5.1.2
with Pressure Limiters
5.1.2
Sensing Bulb Mounting

• Location is important — mount on top of the suction

line.
• On a vertical suction line, capillary tube of the bulb
should always enter from the top of the bulb.
• Clean suction line and bulb with steel wool prior to
assembling.
• Must be wrapped in insulation to make sure only
suction line temperature is read.
5.1.2
Sensing Bulb Mounting
 Thermostatic Expansion Valve
5.1.2

• Capacities vary according to:

• Orifice size. Undersizing can lead to starving of the
evaporator; oversizing can cause hunting/surging
of the valve.
• Pressure difference between the high side and the
low side (increasing pressure difference will
increase the rate of refrigerant flow).
• The temperature and condition of the refrigerant
in the liquid line.
 Questions

• What results from the instantaneous evaporation of a

liquid? Flash gas.

• When flash gas is present in a liquid line, what happens to

the capacity of an expansion valve?
It decreases.

• Which component can be used to reduce flash gas?

A heat exchanger.
 Questions
continued

• When measuring superheat, what two temperatures must

be known?
Evaporator saturation temperature and sensing bulb
temperature.

• Which will cause a starved evaporator: an increase or a

decrease in superheat?
An increase in superheat.

• Which two TEV sensing bulbs do not use the same

refrigerant that is in the system?
A liquid cross-charged bulb and a gas cross-
charged bulb.
5.1.3
Solenoid Valve Principles

• Consists of a movable armature made of an iron alloy

and attached to the valve needle, all sealed into a
valve body.
• Coil is wound around the valve housing that contains
the armature.
• May be activated by a thermostat.
• Used to control the temperature of a refrigerator or
room.
5.1.3
Solenoid Valve Principles
5.1.3
Types of Solenoid Valves

• Two-way valve —
controls flow of
refrigerant through
a single line.
5.1.3 Types of Solenoid Valves
continued

• Three-way valve with an

inlet that is common to
two opposite openings.
• Controls refrigerant
flow in two different
lines. (Used mainly on
commercial refriger-
ating units).
5.1.3
Types of Solenoid Valves
continued

• Four-way reversing valve

— used on heat pumps.
5.1.3
Types of Solenoid Valves
continued

• Pilot-operated solenoid
valve — used for large
commercial applications.
5.1.3
Equalizer

• Compensates for any pressure drop through the

evaporator while the compressor is running.
• Used if the pressure drop between the inlet of the
evaporator and the outlet is more than 4 psi (28kPa).
• Provides the same pressure as that in the suction line
at the sensing bulb location.
• Equalization of pressure permits accurate
superheating adjustments.
5.1.3
Equalizer
5.1.3
Hunting

• Sometimes referred to as surging, hunting occurs

when a valve first opens too wide, then closes down
too much.
• When a valve is hunting excessively, refrigerant flow
provided to the evaporator is not uniform.
• The less hunting, the more effective the system will
be.
• Liquid may reach the compressor and cause damage.
• Hunting can be caused by a valve that is too large for
the system.
5.1.4
Low-Side Float

• A simple and efficient refrigerant control method.

• Used with large industrial systems and in some water
cooling systems.
• Requires a means of returning excess oil to
compressor. Extending the suction tube to the bottom
of the float pan ensures oil return.
• May use a pressure-operated motor control or a
thermostatic motor control.
5.1.4
Low-Side Float
5.1.5
High-Side Float

• Located in the high-pressure side of the system.

• Evaporator must be equipped with a special oil return.
• May use either a thermostatic or a pressure-operated
motor control.
5.1.5
High-Side Float
5.1.6
Capillary Tube

• Acts as a constant throttle on the system.

• Equipped with a filter or a filter-drier to remove
moisture or dirt from refrigerant.
• Amount of refrigerant must be carefully calculated.
• Must be used with a thermostatic motor control.
• Fittings must be leak-proof.
5.1.6
Capillary Tube
 Comparing Refrigerant Controls
5.2

Note: Pressure-time cycle varies with refrigerant used.

5.3
Check Valves

• Limit the directional flow of refrigerant.

• Rotary and gear compressors have check valves in the
suction line, preventing high-pressure vapor and
refrigerant oil from backing up into the evaporator.
• May use either a disk or solid ball in construction.
• In multiple systems that operate at different
temperatures, check valves keep refrigerant vapors in
warmer evaporators from backing up into the colder
evaporators.
5.3
Check Valves
5.4
Suction Pressure Valves

Evaporator Pressure Regulator (EPR)

• Required on multiple systems in which evaporators
operate at different temperatures.
• Required on most automobile air conditioning
systems due to compressor operating at various
speeds.
Crankcase Pressure Regulator (CPR)
• Used to keep compressor suction pressure at a safe
level.
• Prevents overloading the compressor.
 Questions

• Which type of solenoid valve controls refrigerant flow

through a single line? Two-way valve.

• Where is a four-way reversing valve commonly used?

In a heat pump system.

• Where is a low-side float metering device commonly used?

In large industrial systems.

• Which type of motor control can be used on a low-side

float system? Thermostatic or pressure-operated control.
 Questions
continued

• Which type of motor control can be used on a capillary

tube system? A temperature control.

• What is the purpose of a check valve?

To allow refrigerant to flow in one direction.

• Where is a check valve located on a multiple-evaporator

system? At the outlet of the coldest evaporator.
 Questions
continued

• What is the purpose of an EPR valve (evaporator pressure

regulator)?
It is used to maintain constant evaporator pressure.

• Where is an EPR valve located on a multiple evaporator

system?
At the outlet of the warmer evaporators.

• What is the purpose of a CPR (crankcase pressure

regulator)?
It prevents the compressor from overloading.
5.5
Safety

• Attach a 24-hour pressure-time recorder to any new

installation. It will ensure the system is operating
within safe pressure limits.
• Keep floors clear of debris.
• Wear safety goggles when working on refrigeration
systems.
• When lifting, use leg muscles; do not use your back.
5.5
Safety
continued

• Always have good ventilation and good lighting when

working on systems.
• All electrical circuits must be well-insulated to avoid
shock.
• All metal parts of refrigerating mechanisms should be
grounded.
• When removing a valve from a system, use two
wrenches.
 Glossary

• adsorption
The adhesion of a thin layer of molecules of a gas or liquid to a solid
object. There is no chemical combination between the gas and the solid
substance (adsorber).

• automatic expansion valve

Pressure-controlled valve that reduces high-pressure liquid refrigerant
to low-pressure liquid refrigerant.

• check valve
Device that permits fluid flow in only one direction.

• equalizer
A device used to balance pressure in a system or balance liquid levels
between two containers.
 Glossary

• flash gas
Instantaneous evaporation of some liquid refrigerant in evaporator,
cooling the remaining liquid refrigerant to the desired evaporation
temperature.

• hunting
The process of cycling above and below the set point.

• pressure limiter
Device that remains closed until a certain pressure is reached, then
opens and releases fluid to another part of system or breaks an electric
circuit.

• refrigerant control
Device that meters flow of refrigerant between two areas of a
refrigerating system. Maintains the pressure difference between high-
pressure and low-pressure side of the system while unit is running.
 Glossary

• solenoid valve
Electromagnet with a moving core. It serves as a valve or operates a
valve.

• superheat
The temperature of vapor above its boiling temperature as a liquid at
that pressure or the difference between the temperature at the
evaporator outlet and the lower temperature of the refrigerant
evaporating in the evaporator.

• thermistor
A semiconductor with electrical resistance that varies with
temperature.